Polymeric Fluid Transfer and Printing Devices

Abstract

A method and apparatus for making a polymeric printhead having one or more pins for fluid transfer and printing, including the steps of forming a positive mold of the printhead using a bulk micromachining process, forming a negative mold of the printhead from the positive mold using an electroforming process, and forming the printhead from a polymeric material in the negative mold, the polymeric printhead being operative for fluid transfer and/or printing. Also, printheads and pins, holders and dispensing trays microfabricated from a polymeric materials for fluid transfer and printing.

1 . An apparatus for fluid transfer, the apparatus comprising:
 a pin microfabricated from a polymeric material, the pin for transferring a predetermined volume of a fluid, the pin having a tip and a fluid reservoir communicating with the tip.   
     
     
         2 . The apparatus according to  claim 1 , further comprising a holder microfabricated from a polymeric material, the holder having a first member for holding the pin. 
     
     
         3 . The apparatus according to  claim 2 , wherein the holder further comprises a second member for collimating the pin. 
     
     
         4 . The apparatus according to  claim 1 , further comprising a head member having surfaces for collimating the pin. 
     
     
         5 . The apparatus according to  claim 1 , further comprising a head member and a spring coupling the pin to the head member. 
     
     
         6 . The apparatus according to  claim 1 , further comprising at least a second pin, the pins forming an array. 
     
     
         7 . The apparatus according to  claim 6 , further comprising a dispensing tray microfabricated from a polymeric material, the dispensing tray having an array of wells corresponding to the array of pins, for holding liquid to be transferred by the array of pins. 
     
     
         8 . The apparatus according to  claim 6 , wherein the array of pins comprises up to 100,000 pins. 
     
     
         9 . The apparatus according to  claim 7 , wherein the array of pins comprises up to 100,000 pins. 
     
     
         10 . The apparatus according to  claim 6 , wherein the array of pins form a pin density between about 10 −4  and 10 6  pins/mm 2 . 
     
     
         11 . The apparatus according to  claim 7 , wherein the array of pins form a pin density between about 10 −4  and 10 6  pins/mm 2 . 
     
     
         12 . The apparatus according to  claim 1 , further comprising a head member and at least a second pin, the pins forming an array, the pins of the array unitarily formed with the head member to define a first printhead. 
     
     
         13 . The apparatus according to  claim 12 , further comprising a dispensing tray microfabricated from a polymeric material, the dispensing tray having an array of wells corresponding to the array of pins, for holding liquid to be transferred by the array of pins. 
     
     
         14 . The apparatus according to  claim 12 , wherein the array of pins comprises up to 100,000 pins. 
     
     
         15 . The apparatus according to  claim 13 , wherein the array of pins comprises up to 100,000 pins. 
     
     
         16 . The apparatus according to  claim 12 , wherein the array of pins form a pin density between about 10 −4  and 10 6  pins/mm 2 . 
     
     
         17 . The apparatus according to  claim 13 , wherein the array of pins form a pin density between about 10 −4  and 10 6  pins/mm 2 . 
     
     
         18 . The apparatus according to  claim 12 , further comprising at least a second printhead assembled together with the first printhead to form a two dimensional array of the pins. 
     
     
         19 . The apparatus according to  claim 18 , further comprising a holder for assembling the printheads together. 
     
     
         20 . The apparatus according to  claim 19 , wherein the head members of the printheads are configured to self-align the printheads with the holder. 
     
     
         21 . The apparatus according to  claim 12 , further comprising a holder for holding the first printhead. 
     
     
         22 . The apparatus according to  claim 21 , wherein the head member is configured to self-align the first printhead relative to the holder. 
     
     
         23 . The apparatus according to  claim 1 , wherein the predetermined volume comprises between about 0.1 mL and 10 −4  pL. 
     
     
         24 . The apparatus according to  claim 1 , wherein pin is capable of printing a spot having an area of about 10 mm 2  and 10 −6  μm 2 . 
     
     
         25 . A pin comprising:
 a tip; and   a fluid reservoir communicating with the tip,   wherein the pin is microfabricated from a polymeric material and is operative for transferring a predetermined volume of a fluid.   
     
     
         26 . The pin according to  claim 25 , further comprising a head for suspending the pin in a holder. 
     
     
         27 . The pin according to  claim 26 , wherein the tip of the pin is configured for printing or dispensing the fluid. 
     
     
         28 . The pin according to  claim 25 , further comprising a spring opposite the tip for biasing the pin. 
     
     
         29 . The pin according to  claim 25 , wherein the predetermined volume comprises between about 0.1 mL and 10 −4  pL. 
     
     
         30 . The pin according to  claim 25 , wherein pin is capable of printing a spot having an area of about 10 mm 2  and 10 −6  μm 2 . 
     
     
         31 . A holder for use in fluid transfer and printing, the holder comprising:
 a first member; and   a first aperture formed in the first member for receiving a microfabricated pin for transferring a predetermined volume of a fluid,   wherein the holder is microfabricated from a polymeric material.   
     
     
         32 . The holder according to  claim 31 , further comprising at least a second aperture to form an array of apertures for receiving a microfabricated array of pins. 
     
     
         33 . The holder according to  claim 32 , wherein the array of apertures comprises up to 100,000 apertures. 
     
     
         34 . The holder according to  claim 32 , wherein the array of apertures form an aperture density between about 10 −4  and 10 6  apertures/mm 2 . 
     
     
         35 . The holder according to  claim 31 , further comprising:
 a second member having a second aperture axially aligned with the first aperture.   
     
     
         36 . A dispensing tray for use in fluid transfer and printing, the dispensing tray comprising:
 a well for holding a fluid to be transferred by a microfabricated pin for transferring a predetermined volume of a fluid,   wherein the tray is microfabricated from a polymeric material.   
     
     
         37 . The dispensing tray according to  claim 36 , further comprising at least a second well to form an array of wells for holding fluid to be transferred by a microfabricated array of pins. 
     
     
         38 . The dispensing tray according to  claim 37 , wherein the array of wells comprises up to 100,000 wells. 
     
     
         39 . The dispensing tray according to  claim 37 , wherein the array of wells form a well density between about 10 −4  and 10 6  wells/mm 2 . 
     
     
         40 . A method comprising steps of:
 forming a positive mold of an article using a bulk micromachining process;   forming a negative mold of the article from the positive mold using an electroforming process; and   forming the article from a polymeric material in the negative mold, the polymeric article being operative for fluid transfer and printing.   
     
     
         41 . The method according to  claim 40 , wherein the article comprises a pin for transferring a predetermined volume of a fluid. 
     
     
         42 . The method according to  claim 41 , wherein the article further comprises a head member having surfaces for collimating the pin. 
     
     
         43 . The method according to  claim 41 , wherein the article further comprises a head member and a spring coupling the pin to the head member. 
     
     
         44 . The method according to  claim 41 , wherein the article further comprises at least a second pin, the pins forming an array. 
     
     
         45 . The method according to  claim 44 , wherein the array of pins comprises up to 100,000 pins. 
     
     
         46 . The method according to  claim 44 , wherein the array of pins form a pin density between about 10 −4  and 10 6  pins/mm 2 . 
     
     
         47 . The method according to  claim 41 , wherein the predetermined volume comprises between about 0.1 mL and 10 −4  pL. 
     
     
         48 . The method according to  claim 41 , wherein pin is capable of printing a spot having an area of about 10 mm 2  and 10 −6  μm 2 . 
     
     
         49 . The method according to  claim 41 , wherein the article further comprises a head member and at least a second pin, the pins forming an array, the pins of the array being unitary with the head member to define a first printhead. 
     
     
         50 . The method according to  claim 49 , further comprising the step of assembling at least a second printhead together with the first printhead to form a two dimensional array of the pins. 
     
     
         51 . The method according to  claim 41 , wherein the pin includes a head for suspending the pin in a holder. 
     
     
         52 . The method according to  claim 51 , wherein the pin further includes a tip for printing or dispensing a fluid. 
     
     
         53 . The method according to  claim 41 , further comprising a spring opposite the tip for biasing the pin. 
     
     
         54 . The method according to  claim 40 , wherein the article comprises a fluid dispensing tray, the dispensing tray having a well for holding a fluid to be handled by a microfabricated pin. 
     
     
         55 . The method according to  claim 54 , wherein the dispensing tray further comprises at least a second well to form an array of wells for holding fluid to be handled by a microfabricated array of pins. 
     
     
         56 . The method according to  claim 55 , wherein the array of wells comprises up to 100,000 wells. 
     
     
         57 . The method according to  claim 55 , wherein the array of wells form a well density between about 10 −4  and 10 6  wells/mm 2 . 
     
     
         58 . The method according to  claim 40 , wherein the article comprises a holder comprising a first member and a first aperture formed in the first member for receiving a microfabricated pin. 
     
     
         59 . The method according to  claim 58 , wherein the first member of the holder further comprises at least a second aperture to form an array of apertures for receiving a microfabricated array of pins. 
     
     
         60 . The method according to  claim 59 , wherein the array of apertures comprises up to 100,000 apertures. 
     
     
         61 . The method according to  claim 59 , wherein the array of apertures form an aperture density between about 10 −4  and 10 6  apertures/mm 2 . 
     
     
         62 . The method according to  claim 40 , further comprising the step of removing flashing from the article. 
     
     
         63 . The method according to  claim 62 , wherein the flashing removing step is performed by at least one of die cutting, computer numerical controlled cutting, and grinding. 
     
     
         64 . The method according to  claim 40 , further comprising the step of polishing surfaces of the article. 
     
     
         65 . The method according to  claim 64 , wherein the polishing step is performed by a chemical polishing process. 
     
     
         66 . The method according to  claim 40 , wherein the bulk micromachining process includes the step of micromachining a silicon wafer or substrate to form at least one mold section. 
     
     
         67 . The method according to  claim 66 , wherein the positive first mold forming step further comprises the step of bonding the at least one mold section to a wafer or substrate. 
     
     
         68 . The method according to  claim 40 , wherein the article forming step is performed by a molding process selected from the group consisting of casting, compression molding, stamping, and injection molding. 
     
     
         69 . The method according to  claim 40 , wherein the polymeric material is selected from the group consisting of polycarbonates and polymethylmethacrylates, polyolefins, and polyetherketones. 
     
     
         70 . The method according to  claim 40 , wherein the polymeric material comprises a thermoplastic polymer. 
     
     
         71 . The method according to  claim 40 , wherein the negative second mold is formed of a metal.